U.S. patent application number 14/814327 was filed with the patent office on 2016-02-04 for systems and methods for conserving water and other resources for use with commercial washing machines.
The applicant listed for this patent is Kevin C. Goodsell. Invention is credited to Kevin C. Goodsell.
Application Number | 20160033086 14/814327 |
Document ID | / |
Family ID | 55179614 |
Filed Date | 2016-02-04 |
United States Patent
Application |
20160033086 |
Kind Code |
A1 |
Goodsell; Kevin C. |
February 4, 2016 |
SYSTEMS AND METHODS FOR CONSERVING WATER AND OTHER RESOURCES FOR
USE WITH COMMERCIAL WASHING MACHINES
Abstract
Systems and related methods for conserving various resources,
such as, but not limited to, water, laundry chemicals, natural gas,
electricity, linen, labor, and wear on equipment (e.g., a solenoid
valve of a commercial washing machine drain line). The inventor has
spent the past 14 years in the industrial chemical field, allowing
him to access and service commercial washing machines, and has
discovered that drain issues relative to such commercial washing
machines result in enormous losses to such institutions that
process a large volume of laundry. Such typical institutions
include, but are not limited to, hotels, hospitals, prisons,
universities, colleges, laundries, and nursing homes. By replacing
a portion of the opaque drain pipe section between the valve and
the floor drain, operators and technicians can quickly determine if
a leak is occurring, and take corrective action. An access port may
also be provided to test characteristics of discharged wash
water.
Inventors: |
Goodsell; Kevin C.; (Roy,
UT) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Goodsell; Kevin C. |
Roy |
UT |
US |
|
|
Family ID: |
55179614 |
Appl. No.: |
14/814327 |
Filed: |
July 30, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62032337 |
Aug 1, 2014 |
|
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|
Current U.S.
Class: |
137/15.17 ;
137/559 |
Current CPC
Class: |
F17D 5/02 20130101; D06F
2226/00 20130101; D06F 39/083 20130101; F17D 3/01 20130101; G01N
33/18 20130101 |
International
Class: |
F17D 5/02 20060101
F17D005/02; G01N 33/18 20060101 G01N033/18; F16L 55/07 20060101
F16L055/07; D06F 39/08 20060101 D06F039/08; F17D 3/01 20060101
F17D003/01 |
Claims
1. A system configured to conserve resources, for use with a
commercial laundry washing machine including a valve within a drain
pipe section through which wash water from the washing machine is
discharged into a waste water treatment or disposal system, the
system comprising: a portion of the drain pipe section exterior to
the washing machine and upstream from where the drain pipe empties
into a floor drain, wall drain, or other drain location of the
waste water treatment or disposal system that is inaccessible as a
practical matter, the portion of the drain pipe section exterior to
the washing machine being of a transparent material so as to allow
an operator or technician to visually ascertain if water is
draining through the transparent portion of the drain pipe section
even though the valve is attempting to close.
2. A system as recited in claim 1, wherein the valve is a solenoid
valve.
3. A system as recited in claim 1, wherein the transparent portion
of the drain pipe section is downstream from the valve and upstream
from the floor drain, wall drain, or other drain location of the
waste water treatment or disposal system.
4. A system as recited in claim 1, wherein the transparent portion
of the drain pipe section further comprises an access port through
a top surface of the transparent portion of the drain pipe section
so as to be out of a flow path of wash water in the transparent
portion of the drain pipe section to allow a technician to insert a
test strip through the access port into the wash water discharged
from the washing machine to test pH, bleach concentration, or other
chemical characteristics of the discharged wash water.
5. A system as recited in claim 4, wherein the access port includes
an elbow including an inlet leg, at least the proximal end of the
inlet leg being disposed exterior to the drain pipe section, the
inlet leg being disposed adjacent an outlet leg of the elbow, the
outlet leg leading into a top interior portion of the transparent
portion of the drain pipe section, oriented so that the outlet leg
extends towards a bottom interior portion of the transparent
portion of the drain pipe section.
6. A system as recited in claim 5, wherein the inlet leg is
oriented so as to be substantially perpendicular and laterally
sideways relative to a longitudinal axis of the portion of the
drain pipe section in which the access port is disposed, the outlet
leg being oriented so as to be substantially perpendicular and
downward relative to the longitudinal axis of the portion of the
drain pipe section in which the access port is disposed.
7. A system as recited in claim 6, wherein the outlet leg is
substantially perpendicular relative to the inlet leg.
8. A system as recited in claim 6, wherein the distal end of the
outlet leg disposed within the interior of the drain pipe section
includes a sidewall which is tapered so as to be longer on an
upstream side versus the downstream side.
9. A system as recited in claim 8, wherein an opening in the distal
end of the outlet leg includes a curved scooped shape so that the
upstream portion of the sidewall serves as a shield to minimize or
prevent wash water flowing within the drain pipe section from
entering into the access port.
10. A system as recited in claim 1, wherein the system further
comprises the commercial laundry washing machine including a valve
within a drain pipe section through which wash water from the
washing machine is discharged into a waste water treatment or
disposal system.
11. A system configured to conserve resources, for use with a
commercial laundry washing machine including a solenoid valve
within a drain pipe section through which wash water from the
washing machine is discharged into a waste water treatment or
disposal system, the system comprising: a portion of the drain pipe
section exterior to the washing machine, downstream from the
solenoid valve, and upstream from where the drain pipe empties into
a floor drain or wall drain that provides access to the waste water
treatment or disposal system being of a transparent material so as
to allow an operator or technician to visually ascertain if water
is draining through the transparent portion of the drain pipe
section even though the solenoid valve is attempting to close; the
transparent portion of the drain pipe section further comprising an
access port through a top surface of the transparent portion of the
drain pipe section to allow a technician to insert a test strip
through the access port into wash water discharged from the washing
machine to test pH, bleach concentration, or other chemical
characteristics of the discharged wash water.
12. A system as recited in claim 11, wherein the system further
comprises the commercial laundry washing machine including a
solenoid valve within a drain pipe section through which wash water
from the washing machine is discharged into a waste water treatment
or disposal system.
13. A method of conserving resources, the method comprising:
providing a transparent portion to a drain pipe of a commercial
washing machine, which transparent portion is exterior to the
washing machine, downstream from a valve of the drain pipe
associated with the washing machine, and upstream from where the
drain pipe empties into a drain that provides access to a waste
water treatment or disposal system, which allows an operator or
technician to visually ascertain if wash water is draining through
the transparent drain pipe portion even though the valve of the
drain pipe associated with the washing machine is attempting to
close; and periodically checking or instructing a user to check the
transparent drain pipe portion to determine if wash water is
draining through the transparent drain pipe portion even though the
valve is attempting to close; and repairing or replacing, or
instructing a user to repair or replace the valve when wash water
is determined to be draining through the transparent drain pipe
portion even though the valve is attempting to close.
14. A method as recited in claim 13, wherein the valve is a
solenoid valve.
15. A method as recited in claim 13, wherein providing a portion of
the drain line comprises retrofitting the portion of the drain line
of the commercial washing machine by replacing a portion of an
opaque drain pipe section exterior to the washing machine and
upstream from where the drain line empties into the waste water
treatment or disposal system with a transparent drain pipe section,
which allows an operator or technician to visually ascertain if
water is draining through the transparent drain pipe portion even
though a valve of the drain line associated with the washing
machine is attempting to close.
16. A method as recited in claim 13, wherein the drain that
provides access to a waste water treatment or disposal system is in
a floor or wall.
17. A method as recited in claim 13, wherein the transparent drain
pipe portion is checked each day of use of the commercial washing
machine to determine if wash water is draining through the
transparent drain pipe portion even though the valve is attempting
to close.
18. A method as recited in claim 13, the method further comprising
inserting or instructing a technician to insert a test strip
through an access port provided in the transparent drain pipe
portion, into wash water discharged from the washing machine to
test pH, bleach concentration, or other chemical characteristics of
the discharged wash water.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] The present application claims the benefit of U.S.
Provisional Patent Application Ser. No. 62/032,337, filed Aug. 1,
2014, entitled "SYSTEMS AND METHODS FOR CONSERVING WATER AND OTHER
RESOURCES FOR USE WITH COMMERCIAL WASHING MACHINES," the disclosure
of which is herein incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. The Field of the Invention
[0003] The present invention is in the field of commercial washing
machines, and more particularly to methods for reducing waste of
valuable resources, such as water, laundry chemicals (e.g.,
detergent, bleach, softener, etc.), fuels or other energy used to
heat water, linens, etc.
[0004] 2. The Relevant Technology
[0005] Commercial washing machines are routinely employed in
various institutions that generate large volumes of linen (e.g.,
towels, bedding, clothing, etc.) to be laundered. Such commercial
washing machines are of a size that is significantly larger (e.g.,
60 lb or more capacity) than those employed in residential
environments, and are configured differently so that they drain
from the bottom of the machine. In contrast, residential washing
machine models may drain from anywhere along the back of the
machine, but include a siphon break that forces the water in the
drain line to run up the wall above the top water level associated
with the washing machine, before draining into the residential
sewer line. The siphon break prevents water from being
inadvertently siphoned, or pulled into the sewer line, so that it
only drains from the washer when desired (e.g., pumped
therefrom).
[0006] In addition, such commercial washing machines typically
operate on a more sophisticated wash cycle, by which a portion of
the wash water is added during sub cycles of the overall wash
cycle. The chemicals for the overall wash cycle are also added
sequentially (and automatically), rather than all at once. For
example, such a washer may add a portion of the wash water (e.g.,
about 13 gallons for a 60 lb capacity washer) for a first sub cycle
or portion of the overall wash cycle, the water may be at least
partially drained, and new wash water added for a subsequent
portion of the wash cycle, etc. Such washers may include 2, 3, or
more such sub cycles in the overall wash cycle. In addition, the
chemicals (e.g., detergent, bleach, softener, etc.) may typically
be added automatically and sequentially, during the respective sub
cycle portions of the overall wash cycle, as opposed to addition of
all or most all chemicals at once (e.g., manually), as is the case
in residential size washers. Such commercial washers are also
typically programmable, so that the operator or technician may
customize the various parameters associated with the various sub
cycles of the overall wash cycle (e.g., cycle time, water added,
chemicals added and how much, etc.).
[0007] Commercial washing machines typically include a solenoid
valve within the drain line of the washing machine, which operates
to selectively open and close a valve door in the drain line,
allowing the wash water to be discharged, as needed.
BRIEF SUMMARY
[0008] The present invention relates to systems and methods for
conserving resources associated with commercial laundry washing
machines. An exemplary system may include a commercial laundry
washing machine including a valve within a drain pipe section
through which wash water from the washing machine is discharged
into a waste water treatment or disposal system. The system may
further include a portion of the drain pipe section exterior to the
washing machine and upstream from where the drain pipe empties into
a floor drain, wall drain, or other drain location of the waste
water treatment or disposal system that is inaccessible as a
practical matter, the portion of the drain pipe section exterior to
the washing machine being of a transparent material so as to allow
an operator or technician to visually ascertain if water is
draining through the transparent portion of the drain pipe section
even though the valve (e.g., a solenoid valve) is attempting to
close. The transparent portion of the drain pipe section may
further comprise an access port through a top surface of the
transparent portion of the drain pipe section so as to be out of a
flow path of wash water in the transparent portion of the drain
pipe section to allow a technician to insert a test strip through
the access port into the wash water discharged from the washing
machine to test pH, bleach concentration, or other chemical
characteristics of the discharged wash water.
[0009] An exemplary method of conserving resources may include
providing a transparent portion to a drain pipe of a commercial
washing machine, which transparent portion is exterior to the
washing machine, downstream from a valve of the drain pipe
associated with the washing machine, and upstream from where the
drain pipe empties into a drain that provides access to a waste
water treatment or disposal system, which allows an operator or
technician to visually ascertain if wash water is draining through
the transparent drain pipe portion even though the valve of the
drain pipe associated with the washing machine is attempting to
close. The method may further include periodically (e.g.,
regularly, such as every day) checking the transparent drain pipe
portion to determine if wash water is draining through the
transparent drain pipe portion even though the valve is attempting
to close. The method may further include repairing or replacing the
valve when wash water is determined to be draining through the
transparent drain pipe portion even though the valve is attempting
to close.
[0010] Additional features and advantages will be set forth in part
in the description that follows, and in part will be obvious from
the description, or may be learned by practice of the embodiments
disclosed herein. The objects and advantages of the embodiments
disclosed herein will be realized and attained by means of the
elements and combinations particularly pointed out in the appended
claims. It is to be understood that both the foregoing brief
summary and the following detailed description are exemplary and
explanatory only and are not restrictive of the embodiments
disclosed herein or as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] To further clarify the above and other advantages and
features of the present invention, a more particular description of
the invention will be rendered by reference to specific embodiments
thereof which are illustrated in the drawings located in the
specification. It is appreciated that these drawings depict only
typical embodiments of the invention and are therefore not to be
considered limiting of its scope. The invention will be described
and explained with additional specificity and detail through the
use of the accompanying drawings in which:
[0012] FIG. 1 shows an exemplary system according to the present
invention;
[0013] FIG. 2 is a close up view showing an exemplary access port
included in a transparent drain pipe section according to the
present invention; and
[0014] FIG. 3 is a close up view of another exemplary access
port.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
I. Introduction
[0015] The present invention relates to systems and related methods
for conserving various resources, such as, but not limited to,
water, laundry chemicals (e.g., detergent, bleach, softeners,
etc.), natural gas, electricity, linen, labor, and wear on
equipment. The inventor has spent the past 14 years in the
industrial chemical field which has allowed him access to
commercial washing machines, at times servicing commercial washing
machines, and has discovered that drain issues relative to such
commercial washing machines result in enormous losses to such
institutions that process a large volume of laundry. Such typical
institutions include, but are not limited to, hospitality (e.g.,
hotels, motels, bed and breakfasts), hospitals, corrections (e.g.,
prisons, jails, youth detention centers, etc.), universities,
colleges, laundries (including dry and "wet" cleaners), commercial
laundries (model linens), fire stations, athletic institutions
(e.g., college, professional, etc.), car washes, dairies, food
processing facilities (e.g., meat plants), maritime facilities
(e.g., cruise ships, coast guards, etc.), restaurants, spas,
salons, long term care facilities, and nursing homes.
[0016] In the inventor's experience, perhaps two-thirds of all such
institutions' commercial washing machine installations have chronic
leak issues associated with the drain systems for selectively
draining the wash water from the commercial washing machine. In
effect, the inventor has discovered that if the drain lines of such
commercial washing machines are inspected, about two-thirds of them
exhibit a leak where the wash water that is supposed to be held
within the washer during select portions of the wash cycle is
instead slowly (or not so slowly) leaking out of the drain line of
the washing machine system. Such a leak (which may often appear as
a continuous trickle to full on gush out of the drain system) may
appear to the labor force called upon to operate such commercial
washing machines as insignificant, and a mere nuisance, although
the inventor has discovered that it is actually the root of a much
larger and overall costly issue.
[0017] The inventor has discovered a simple solution to the present
problem, which relies on education, associated intervention, and a
modification to the drain pipe section exterior to the washing
machine, downstream from the valve (e.g., solenoid valve)
associated with the washing machine that is supposed to close
during select portions of the wash cycle so as to hold the wash
water in the washing machine. The modified drain pipe section is
exterior to the washing machine, downstream from the described
drain valve, and upstream from where the drain pipe empties into
the floor drain or similar drain, of a larger (e.g., municipal)
waste water treatment or disposal system. Once the water enters
such drain (e.g., the drain of the building in the room in which
the washers are located), it and the piping carrying it is
inaccessible as a practical matter.
[0018] For example, a system according to the present invention
includes a commercial laundry washing machine that includes a valve
(e.g., a solenoid valve) within a drain pipe section through which
wash water from the washing machine is discharged into a waste
water treatment or disposal system (e.g., a municipal water
treatment system). In another embodiment, the system itself may not
necessarily include the washing machine, but is of course for use
with the washing machine (e.g., in a retrofit). In existing
installations, there is a drain pipe section exterior to the
washing machine (e.g., exiting behind and at the bottom of the
washing machine), upstream from where the drain pipe empties into
the floor drain or similar drain. This section, often only 3-4 feet
(e.g., rarely longer than 15 feet) in length simply serves to carry
the dirty wash water out of the washing machine, and into the waste
water treatment or disposal system (e.g., the sewer) through the
building drain. This drain pipe section in existing installations
is formed of an opaque (e.g., black or white) pipe material (e.g.,
opaque, black or white 3 inch PVC pipe). Because the drain pipe is
opaque, the operator cannot readily see if any leak is present.
[0019] The present invention employs a transparent drain pipe
section for at least a portion (e.g., typically all) of this drain
pipe section that is exterior to the washing machine, downstream
from the valve, and upstream from where the drain pipe empties into
the drain serving as the entrance into the larger waste water
treatment or disposal system. Employing a transparent pipe portion
is a simple, but elegant solution that advantageously allows a
technician or operator to readily visually ascertain if water is
draining through the transparent portion of the drain pipe section,
even though the solenoid valve is attempting to close (i.e., the
wash water is supposed to be held within the washing machine). This
often occurs when fibers or degraded linens, coins, or other debris
becomes trapped against the valve door, preventing its full
closure, as explained herein. Unless such debris is removed, the
valve will unsuccessfully try to close as usual, eventually burning
out.
[0020] Absent recognition of the particular problem to be solved,
one would not readily choose to include a transparent drain pipe
section as described above, as such transparent piping is many
times more expensive than the typically employed opaque PVC
piping.
[0021] Such a transparent portion of the drain pipe may further
comprise an access port through the top surface (e.g., so as to be
out of a flow path of wash water in the transparent portion of the
drain pipe section) of the transparent portion of the drain pipe
section. This allows a technician to insert a test strip or other
testing equipment through the access port, into wash water
discharged from the washing machine in order to test pH, bleach
concentration, or other chemical characteristics of the discharged
wash water. Without such an access port, it is impossible to test
the wash water, as it only travels through the opaque drain pipe,
and into the drain or sewer system, so that no access is possible.
Because the modified pipe section is transparent, it is easy to
visually confirm that the test strip actually contacts the wash
water to be tested. This allows the technician to quickly identify
other problems that may be present in the overall system (e.g., a
problem with the chemical dispensing system that automatically
dispenses laundry chemicals into the washing machine).
[0022] A related method includes providing such a transparent
portion in a drain pipe section of a commercial washing machine,
which transparent portion is exterior to the washing machine and
upstream from where the drain pipe empties into the floor (and
downstream from the solenoid valve or other valve which selectively
holds or drains the wash water). This allows the technician or
operator to visually ascertain if wash water is draining through
the transparent drain pipe portion, even though the valve of the
drain pipe associated with the washing machine is attempting to
close. For example, the motor of such a valve (e.g., solenoid
valve) may continuously attempt to close, but full closure may be
impeded by linen fibers or other debris wedged between the valve
door attempting to close and an adjacent sidewall of the valve.
Such a condition will generally cause the solenoid motor of the
valve to fail prematurely (i.e., it burns out).
[0023] A technician or operator may periodically (e.g., regularly,
such as every day of use) check the transparent drain pipe portion
to determine if wash water is draining through the transparent
drain pipe portion, even though the solenoid valve is supposed to
be closed. In the event that the wash water is draining, even when
the valve is supposedly closed, the solenoid valve is repaired
(e.g., cleaned and debris removed) or replaced. As described above,
such leaking through the supposedly closed valve is often caused by
strings or fibers of linen (e.g., generated from degrading linen)
discharged with the wash water becoming caught in the solenoid
valve, which prevents it from fully closing. Removing such linen or
other debris materials from the solenoid valve allows the valve to
again operate properly, holding the wash water in the washing
machine until it is intended to be discharged.
II. Exemplary Systems and Methods
[0024] The slow leaking of a commercial washing machine through its
drain line has not been regarded as a sign of a much larger
problem, but merely as a nuisance. The fact is that when the
commercial washing machine leaks, there is collectively a large
amount of water being wasted as it continually drains, so long as
the washing machine is running. When multiplied over the many
commercial washing machines within a given institution, and over a
metropolitan area, the volume of wasted water is very large (e.g.,
likely thousands of cubic feet of water, tens of thousands of cubic
feet of water, or more in a month).
[0025] In addition, the drain valve (e.g., a solenoid valve) will
continue to try to shut, but will not be able to do so completely,
due to the linen fibers, strings, or other debris trapped in the
valve. Because of the valve's continuously attempting to shut, the
valve wears out much faster than it would under normal operating
circumstances, where it can properly and fully shut. For example,
if properly cared for, a solenoid valve as used in a commercial
washing machine may typically last about 2-5 years, depending on
the facility. Where the solenoid valve has linen fibers, coins, or
other debris trapped against the valve door that is attempting to
shut, the solenoid motor will often burn out in a matter of weeks
(e.g., less than about 10 weeks), as it is continuously trying to
shut so long as the washer is running and a signal is sent to the
solenoid to close the valve. Thus, solving this problem allows the
solenoid valve to be used over its full lifetime which is
significantly longer (e.g., 10 times longer or more). It also
conserves the electricity that is otherwise continuously being
consumed to run the solenoid motor, which is continuously trying to
shut, so long as the valve door is clogged and the valve is
attempting to close.
[0026] In addition, the water leaking through the commercial
washing machine, the solenoid valve, and out the drain pipe is
typically hot water. In addition to the water wastage described
above, there is collectively an enormous energy expenditure to heat
that water that is simply being continuously discharged down the
drain, so long as the commercial washing machine is running with
the leak. For example, where the water heater employs natural gas
in heating the water fed into the commercial washing machine, there
is an associated conservation of natural gas that is then not
consumed to heat the water that is otherwise being discharged down
the drain. Where the water heater is electric, there is an
associated conservation of electricity which is not consumed in
heating the otherwise discharged water.
[0027] By way of example, if the constant trickle of water is at a
rate of about 1-2 liters every 5 minutes, that equates to about
0.05-0.06 gallons per minute (GPM) (for 1 liter every 5 minutes).
Where the water is leaking faster, (e.g., a full on gush), the loss
is far greater (e.g., by a factor of 10 or more). Such commercial
machines are often run at a rate of 12 loads or more per day, per
machine (e.g., about 8-10 hours per day, per machine). In an
installation of 2 machines, this trickle may collectively amount to
50 to 70 gallons of wasted hot water per day, based on a 1 liter/5
minute trickle. For a single installation, this amounts to over
20,000 gallons of wasted hot water per year. When multiplied over
dozens or hundreds of institutions within a municipal area, the
collective waste, just in terms of water and energy wasted to heat
that water (even just directly from the leak) is enormous (e.g.,
millions of gallons of water per month or per year). When
additional water use necessitated by the leak is figured in, the
numbers become even larger (e.g., double, triple, or even a factor
of 10 greater). A 2 liter/5 minute trickle would exhibit numbers
double those described above.
[0028] Such waste is further exacerbated because the leak causes
those linens in the washing machine to not come clean,
necessitating a "reclaim" load, as described herein, and as will be
understood by those of skill in the art. The reclaim load requires
about another 160 gallons of hot water usage for just a single load
on a typical 60 lb capacity washer. This can easily be 10 times or
more the amount of water directly lost due to the leak (e.g.,
reclaim water usage may be considered to be an indirect loss due to
the leak).
[0029] In the case of a leak that is more than the trickle
described above, (e.g., a full on gush out the back end of the
drain line of the washing machine), the flow rate may be 0.5 GPM to
about 25 GPM, or 1 GPM to 15 GPM (e.g., the machine may fill with
20-35 gallons of water in 60 to 90 seconds at the start of a load).
For a leak flow rate of about 1 GPM, the water loss is about 25
times greater than the losses described above relative to a
trickle. For example, in an installation of 2 machines, such a 1
GPM leak may collectively amount to 1,250 to 1,750 gallons (e.g.,
about 1,500 gallons) of wasted hot water per day. For just that
single installation, this amounts to over 500,000 gallons of wasted
hot water per year. For a 10 GPM leak, the amounts would be 10
times greater than those for a 1 GPM leak.
[0030] One way that such full on gush leaks occur is where the fill
valve responsible for filling the washing machine is clogged or has
gone bad. Such fill valves are routinely referred to as Parker
valves within the field. One manufacturer of such valves is Alsco
Industrial Products located in Lithia Springs, Ga. An example of
such a valve is seen on the 4.sup.th page (numbered page 2) of the
Pocket Hardmount Preventative Maintenance Manual, filed as part of
the above referenced provisional application. Such a valve is more
or less a stop or start fill valve for the washing machine. For
example, the machine sends a signal to the valve saying it needs to
fill the machine. The valve opens, and water flows into the machine
until the appropriate limit is reached, after which the valve is
supposed to close. Rather than properly closing, sometimes a small
particle, piece of metal chip, or other debris that has decayed
away from the pipes or is otherwise present gets stuck in the fill
valve, upstream from the washer. This causes the valve to not close
all the way, and the water may stay running until someone notices
it.
[0031] In the inventor's experience, nearly every time such a
problem has been caught, it is the hot water that has been running
continuously. When this happens the water that comes through the
drain line of the washing machine is not a trickle, but is much
more substantial in flow. One can sometimes hear the rushing water
through the drain system, although typically people do not know
where it is coming from, and it gets forgotten. There is no back-up
or other system that catches this problem, and unfortunately this
happens quite frequently. When this happens water goes straight
through the machine and down the drain which is a major loss of hot
water. This occurs even when the machine is not running (e.g., the
drain valve defaults to "open" when the machine is off). Even
though the Parker fill valve defaults to "close" when the machine
is off, if the machine is on, or the fill valve is faulty, water
may continue to run, and run, and run. When the systems as
described herein are installed one would quickly be able to see the
rushing water coming through the clear drain pipe and know there is
a problem, prompting the operator or technician to call maintenance
personnel and have the problem fixed.
[0032] In addition to conservation of water, electricity, natural
gas, and life of the solenoid valve, there is an enormous savings
or conservation of linen and labor where the leak is quickly
detected and repaired. For example, the inventor has discovered
that when a commercial washing machine constantly leaks during use,
it is difficult to hold the necessary volume of water within the
washing machine, as wash water is constantly leaking out. This
constant leak affects the concentration of detergent, bleach, and
other laundry chemicals within the wash water, as well as the pH of
that wash water. It makes it difficult to maintain target
concentrations of such chemicals, and can lead to variations in
concentration over the wash cycle. While some washers may
automatically recognize that the volume of wash water is constantly
and slowly decreasing, and attempt to add new water to compensate,
this loss of wash water makes it difficult to carefully control
chemical concentrations. For example, where wash water is
preferentially discharged through the leak as compared to chemicals
that may also be entrained therein, the concentration of those
chemicals retained and held in the wash water held in the washing
machine actually increases. This increase can lead to chemical
burns or staining of the linen. It can also result in chemical
burns to those using the linen once it has been laundered. For
example, it is believed that many instances of bed sores in nursing
homes and hospitals are due to chemical burns where residual
chemicals held in the laundered linen are released when contacted
by a patient's sweat, body fluids, or other moisture sources. Upon
contact with water, bleaches, pH adjusters (e.g., bases such as
alkali metal hydroxides) and other chemicals held in such linens
can result in chemically induced bed sores, which are often
chemical burns.
[0033] On the other hand, if the chemicals mixed in the wash water
are preferentially discharged through the leak, the chemical
concentration drops, which can cause laundering to be ineffective
in stain removal. In both instances, the continued addition of
added water to the washing machine to try to compensate for such a
leak further complicates the difficulty of maintaining chemical
concentration and pH values within tightly desired ranges. In view
of this, it will be apparent to one of skill in the art that in
order to effectively clean the linens (e.g., towels, bedding, etc.)
within the washing machine, it is important that these variables be
tightly controlled. Constant leakage of wash water out the back of
the washing machine greatly interferes with the ability to properly
clean the linen in the washing machine.
[0034] As a result of the difficulty in controlling laundering
conditions of chemical concentration and pH, it becomes necessary
to recycle a large volume of linen for an additional treatment,
because of staining in the linen which has not been removed during
the normal wash cycle, or stains that are actually added during the
wash cycle because of contact with too high chemical
concentrations. Such stains also often become set, making their
removal more difficult, if not practically impossible. When running
such an additional treatment (referred to as a reclaim load), the
concentrations of detergent, bleach, and/or other laundry chemicals
added during the wash cycle are drastically higher, in an attempt
to remove the stain. Where a leak remains present, all of the
problems associated with the normal wash cycle remain. Often, a
significant fraction of such retreated linens are not salvageable
(particularly where a leak is present), even with repeat
treatments, and are discarded (e.g., "ragged"), which collectively
represents an enormous cost to the institution.
[0035] In addition, such linens which are repeatedly treated are
also more likely to be damaged by the laundry chemicals themselves,
due to the drastically increased concentration of such chemicals in
the reclaim load wash water, even if the chemical concentrations
are kept within the recommended ranges. For example, the elevated
bleach and detergent concentrations lead to chemical attack of the
fibers of the linen, causing such linens to exhibit shorter usable
lifespan, even if the stains can be removed. For example, such
linens often exhibit a tendency to fray and otherwise deteriorate
along the edges of towels, bedding, and other linen. It is often
these strings and fibers which become separated from the linen, and
clog the solenoid valve. In addition, with higher chemical
concentrations, and where a leak interferes with the ability to
hold the needed volume of wash water within the washing machine,
there is a higher incidence of bleach and sour softener stains,
where the chemicals are too high in concentration (e.g., fully or
nearly undiluted) when in contact with the linen. Such contact
results in tell-tale yellow and other staining of the linens, which
can be difficult if not practically impossible to remove.
[0036] As a result, a typical hotel or other institution, which may
have 500-600 towels, and which might normally hope to only have to
replace that linen once a year, finds it necessary to replace the
linen more often, such as once every few months (e.g., every 3 to 6
months), or even more often if a leak is left unchecked. For
example, a typical medium to large size hotel may replace at least
$1,000 of linen every month under normal attrition circumstances.
Much of this attrition is due to the issues described herein. Where
there is a problem more serious than a chronic small leak, which
can often occur several times a year, the problem of linen loss due
to problems with the commercial washing machine installation is
much greater. Such occurrences lead to linen that is stained or
otherwise damaged piling up in the laundry room, which is
associated with much more expensive losses than the typical $1,000
a month. For example, such hotels may typically experience at least
4-5 major breakdowns with the commercial washing machine
installation, each year. In the inventor's experience, likely three
out of those five break downs are due to drain issues such as
described herein, that the operators could not see. With the
present inventive systems and methods, such problems would be
caught early on, and quickly fixed, saving on repair costs, as well
as the numerous resources as described herein. For example, a
repair technician may charge $85 to $150 just for the trip charge,
on top of a high hourly rate.
[0037] For example, the inventor has observed that if a leak is not
repaired, within a week or two, the entire linen inventory of the
institution looks awful, effectively making it unsuitable for use.
Hotels and similar institutions strive to keep a given "par level"
of linen on hand in order to have extra linen for use. Each par
level refers to the facility having enough linen on hand to
completely change out all linen one time. For example, a hotel may
desire to have a "3" par level of linen on hand, meaning they have
enough linen on hand to completely change out the linen 3 times per
room. For a typical hotel, this may represent tens of thousands of
dollars to $100,000 in linen inventory. A typical hotel may have
about 100 to about 200 rooms. When multiplied across multiple
institutions in a given metropolitan or geographic area, the cost
is many millions of dollars. Expensive linen is destroyed where a
leak goes undetected, and until now, the leak of the washing
machine has not been recognized as the root cause of this
destruction.
[0038] Thus, the mere ignoring of a leak in the commercial washing
machine can quickly lead to a very expensive problem, if not
quickly addressed. In addition, most within the industry (e.g.,
operators, supervisors, and even many technicians) do not recognize
the link between the leak and the expensive waste and damage that
follows. As described above, there is an enormous savings that
could be achieved in water, natural gas, electricity, labor, and
linen costs by simply implementing the present systems and
methods.
[0039] The present invention seeks to address these issues by
providing a mechanism by which the operators and technicians who
work with the commercial washing machines every day can be educated
as to the problem, and can be provided with a mechanism by which a
leak can be identified very soon after it first appears. Once the
leak is identified, it can quickly be repaired (e.g., by removing
linen fibers, coins, or other debris that is blocking the door of
the solenoid valve which is trying to close), so that linen is not
destroyed, the solenoid valve motor does not burn out, and other
resources (e.g., water, chemicals, natural gas, electricity) are
not wasted. Rather, the problem is quickly identified and repaired,
before significant waste or damage can occur.
[0040] As outlined above, the scale of the present problem is not
minor, being limited to a small number of commercial washing
machines. For example, in the inventor's experience, the volume of
water used by one 60 lb commercial washing machine in a typical
large hotel is about 67,000 ft.sup.3 (over 500,000 gallons) per
month. A significant fraction of this is attributable to the
commercial washing machine installation. Where perhaps two-thirds
of such commercial washing machines leak at a slow but steady
trickle due to clogging of the door associated with the solenoid
valve, a significant fraction of this water volume could be
conserved by employing methods and systems as described herein. For
example, a significant fraction of this water volume can be
directly linked to leakage through the system, as it simply passes
through the washing machine and leaks out the back, continuously,
so long as the washing machine is running, and the valve is
attempting to close. This leaking water volume is significant. For
example, in many installations, the washing machines may be run at
a rate of 12 loads per day, per washer. Many installations have 2
or more washers. Another fraction of this water volume, which may
likely be an even higher fraction, can be directly linked to
"reclaim" loads, where linen that was washed, but did not come
clean, is run through the washing machine again, under different
conditions, as described above.
[0041] The waste thus becomes quite large even for a single
installation including 1-3 commercial capacity washing machines at
60 lbs to 80 lbs capacity per machine. The waste of water and other
resources becomes enormously large (e.g., likely representing
millions of gallons of water per year when accumulated over even a
moderately sized metropolitan area). The loss in labor,
electricity, natural gas, chemicals, and other resources easily
reaches into millions of dollars per year over that same
metropolitan area.
[0042] Reclaim loads include much higher levels of chemicals added
to the load in an attempt to "reclaim" that linen which is
otherwise lost (e.g., turned into rags). In addition to the higher
chemical loading, such loads are often run according to a different
wash cycle, which consumes a greater volume of water. For example,
a normal load of white towels run on a 60 lb capacity UniMac or
Milnor commercial washing machine may consume about 116 or 124
gallons of water, per load, respectively (i.e., in either case,
about 120 gallons). A reclaim load of white towels that did not
come clean in the normal load in the same commercial washing
machine is run according to a wash cycle that consumes about 165
gallons, or 150 gallons of water, respectively (i.e., in either
case, about 160 gallons).
[0043] In addition, the cost of chemicals (e.g., detergent, bleach,
softener, etc.) in the reclaim load is significantly more (e.g.,
several times more) than the cost of the normal load. For example,
typical chemical cost of the normal load may be about $1.43 for a
60 lb capacity commercial washing machine. Due to the addition of
additional chemicals, and using more of those chemicals used in the
normal load, the chemical cost when running a reclaim load may be
about $6.44, which is 4 to 5 times greater than that of the normal
load.
[0044] As will be apparent, if the present systems and methods
allow one to not have to run so many reclaim loads, the savings in
chemicals, water (e.g., hot water), labor, electricity, and other
resources is significant for each reclaim load that is not needed
because leaks are being detected and quickly repaired. Leaks
interfere with the ability of the commercial washing machine to
hold the needed volume of wash water. Even though the commercial
washing machine may constantly be trying to replace leaking water,
in the inventor's experience, the results speak for themselves. As
described above, it is not a simple matter of water being lost.
Rather, the inventor has observed that in instances where there is
a leak, it adversely affects the ability of the washing machine to
effectively clean the linen load. As a result, when the load has
finished its cycle, it is likely to not have come clean (e.g., due
to much of the chemicals that should have been held in the wash
water instead leaking out the back end of the washing machine, lack
of control over chemical concentrations due to the leak, etc.). As
a result, much or all of the load may have to be placed aside, to
be rerun in a "reclaim" load. When servicing commercial washing
machine installations, the inventor has often observed bins full of
linens that did not come clean, to be rerun in a reclaim load. The
inventor has observed that there is a correlation between such
installations having a backlog of linen to be "reclaimed" and that
installation having washing machines that are leaking Photos of
such installations where linens to be run in a reclaim load are
stacked in bins are shown in the Appendix of the above referenced
provisional application.
[0045] In environments where water is a scarce resource, such as
the western United States, the problems described represent a
significant waste and loss of a valuable resource. As described
above, water waste is not the only waste associated with this
problem and addressed or conserved by the present invention, as
there is also conservation of laundry chemicals, lengthened life of
linens which are collectively very expensive, conservation of
natural gas and electricity, longer life in the solenoid valve, and
overall lower labor costs, as fewer loads of linens are required to
be retreated.
[0046] FIG. 1 illustrates an exemplary drain system 100 and
upstream solenoid valve 104 where a portion 108 of the drain system
exterior to the washing machine is transparent. The transparent
portion 108 of the drain pipe is downstream from the solenoid valve
104, and upstream from where the drain pipe discharges into the
floor drain or wall drain 107 (i.e., the access point into the
larger waste water treatment or disposal system) allowing the
operator to quickly and easily visually ascertain if the solenoid
valve 104 is unable to fully close, causing a leak.
[0047] FIG. 2 shows a close up of the access port, illustrating a
preferred configuration of the outlet leg of the elbow of the
access port, so as to prevent wash water in the drain pipe from
catching on the outlet leg of the elbow and splashing into and
through the access port, and being propelled to the exterior of the
drain pipe.
[0048] As seen in the Figures, an embodiment of the present
inventive system 100 configured to conserve resources may include a
commercial laundry washing machine 102 including a solenoid valve
104 within a drain pipe section 105 through which wash water from
washing machine 102 is discharged into a waste water treatment or
disposal system 106. A portion 108 of the drain pipe 105 exterior
to the washing machine and upstream from location 106 where the
drain pipe 105 empties into floor drain or wall drain 107 is
advantageously transparent so as to allow a technician or operator
to visually ascertain if water is draining through transparent
portion 108 of drain pipe 105, even though solenoid valve 104 is
attempting to close.
[0049] The transparent portion 108 of drain pipe 105 may further
include an access port 110 substantially through top surface 112 of
transparent portion 108 of drain pipe 105. Access port 110 so
placed advantageously allows a technician to insert a test strip
114 through port 110 into wash water discharged from the washing
machine 102 to test pH, bleach concentration, or other chemical
characteristics of the discharged wash water. Port may be disposed
through the top surface 112 as shown, or substantially (e.g., near)
top surface 112. By substantially, it is meant that the location
may be out of a flow path of wash water in the transparent portion
of the drain pipe section. For example, it may be advantageous to
ensure that the port 110 is not in the bottom of pipe portion 108.
For example, if disposed somewhat off center relative to top 112,
it may still be disposed above a half-way point between the bottom
and top 112 (i.e., closer to top than bottom).
[0050] FIG. 2 illustrates a close up view of an exemplary access
port 110. Port 110 may include an elbow 116 (e.g., about
90.degree.) including an inlet leg 118 and an outlet leg 120. At
least proximal end 118a of inlet leg 118 may be disposed exterior
to drain pipe 108, and may extend substantially perpendicular and
laterally (e.g., sideways) relative to a longitudinal axis A of the
drain pipe section in which the port 110 is disposed. Outlet leg
120, or more particularly at least distal end 120a thereof, may be
disposed interior to drain pipe 108. Outlet leg 120 may lead into a
top interior portion 122 of transparent pipe portion 108, and leg
120 may be oriented so that leg 120 extends towards bottom interior
portion 124, where the discharged wash water flows. Leg 120 may be
substantially perpendicular and oriented downward relative to axis
A of transparent drain pipe portion 108. Legs 118 and 120 may be
substantially perpendicular relative to one another.
[0051] As perhaps best seen in FIG. 2, distal end 120a of leg 120
disposed within the interior of drain pipe 108 may include a
sidewall (e.g., a circular sidewall) 126 which is tapered so as to
be longer on upstream side 128 versus downstream side 130. In the
illustrated embodiment, this taper is achieved by providing the
opening in distal end 120a with a curved, scooped shape so that
upstream portion 128 serves as a shield 132 to prevent or minimize
wash water flowing within drain pipe section 108 from entering into
access port 110. In other words, that portion of opening 120a
adjacent upstream side 128 may be vertically lower in tube section
108 (i.e., closer to the flowing discharged wash water) than that
portion of opening 120a adjacent downstream side 130. For example,
where no taper is provided, or where the downstream side 130 of
sidewall 126 were longer than upstream side 128, there may be a
tendency for flowing wash water to hit the inside surface of
sidewall 126 on side 128, and be propelled up into the lumen of
hollow legs 120 and 118. Rather, the wash water first hits the
exterior surface at 128, rather than its interior surface.
Providing an elbow bend between legs 118 and 120, as well as
providing the described taper and/or curved or scooped opening at
end 120a minimizes or prevents any tendency of the wash water to be
propelled up into port 110, and through the proximal entrance at
end 118a.
[0052] FIG. 3 illustrates another configuration of an access port
that may be included within the present invention. Access port 110'
may be similar to port 110 of FIG. 2, but is shown as including an
exterior inlet leg 118' that is generally vertical, rather than
including an elbow bend between legs 118 and 120. Port 110' is
shown as including a cap 119 which may be coupleable over or in
inlet opening 118a' (e.g., through threads or another suitable
mechanism (e.g., a snap fit or friction fit cap or plug). As shown,
cap 119 may include a tether 121 (e.g., a chain, rope, cord, wire,
etc.) attached to both cap 119 on one end and to leg 118' or pipe
108 at the other end.
[0053] Many installations discharge into a drain in a floor or
wall, as illustrated. Such a drain provides an access point to a
larger waste water treatment or disposal system (e.g., a sewer
system). Once entering drain at the floor or wall 107, the wash
water and the piping conveying it is largely inaccessible, as a
practical matter (e.g., it is encased in a wall, floor,
underground, etc.). As such, it is advantageous that the
transparent section 108 be disposed upstream from such drain. In
some installations, a plurality of commercial washing machines
(e.g., side by side) discharge into a common trough, which trough
then empties into a drain (e.g., in a floor) that leads to the
larger (e.g., municipal) waste water treatment or disposal system.
Photographs of such a trough system are included in the Appendix of
the above referenced provisional application.
[0054] An associated method of use for conserving resources may
include providing a transparent portion 108 to a drain pipe 105 of
a commercial washing machine 102, where the transparent portion 108
is exterior to washing machine 102, and upstream from where drain
pipe 105 empties into a floor drain or wall drain 107. This
advantageously allows an operator or technician to quickly visually
ascertain if wash water is draining through the transparent drain
pipe portion, even though valve 104 is supposed to be closed. The
method further includes periodically checking transparent drain
pipe portion 108 to determine if wash water is draining through the
transparent portion 108, even though valve 104 is supposed to be
closed. Where such leaking is occurring, the method further
comprises repairing or replacing the valve 104 when it is
determined that wash water is draining through transparent pipe
section 108, even though valve 104 is supposed to be closed.
[0055] Such methods may be performed in an environment where the
entire drain pipe 105 is initially of an opaque material (e.g.,
opaque PVC), where a portion 108 thereof is removed and replaced
(e.g., retrofitted) with a transparent pipe section 108. As
described above, the section of drain pipe between the washing
machine and the drain that accesses the waste water treatment or
disposal system (e.g., sewer) may often be 3 to 4 feet, or as much
as 15 feet in length. All or just a portion of such pipe section
may be retrofitted or provided so as to be transparent. All that is
required is a sufficiently long transparent section (e.g., a foot
or two, at least), that allows an operator or technician to
visually determine whether a leak is occurring or not. Of course,
it may be easier and preferable to simply replace the entire opaque
pipe section, as it is typically not particularly long, and avoids
any complications associated with splicing in a new pipe
section.
[0056] Once such retrofitting occurs, or in a new installation
where a portion 108 of the drain pipe is specifically installed so
as to be transparent, the operator(s) of the commercial washing
machine may be instructed to periodically and regularly (e.g., each
day) check transparent pipe section 108 to determine if there is a
leak. In the event of a leak, a service technician is contacted so
that valve 104 can be repaired (e.g., cleaned to remove fibrous
linen strings, coins, or other debris), or replaced if the valve is
broken (e.g., the motor has burned out), or repair or replacement
of a faulty fill valve. In an embodiment, a leaking washing machine
may be taken off line and not used until the leaking valve is
repaired or replaced, particularly if there are sufficient washing
machines that the leaking machine does not need to be used. Repair
may preferably occur within 1-3 days.
[0057] Without recognition of the problems that result from not
recognizing and fixing such leaks, there is no reason one would
include a transparent portion in the pipe section, as transparent
PVC is much more expensive than the ordinarily used opaque PVC pipe
materials. For example, transparent 3 inch inside diameter PVC pipe
currently costs about 3 to 4 times the cost of otherwise similar
parts formed from the standard opaque 3 inch diameter pipes.
[0058] Such methods advantageously enable problems caused by a leak
to be quickly addressed, rather than allowing the washing machine
to continue to leak. Although to many such a leak may appear
insignificant, as described herein, such a leak is the root cause
of numerous problems that quickly become expensive in both cost and
resource consumption if left unfixed.
[0059] In addition, the presence of access port 110 in drain pipe
105 (particularly in transparent section 108--allowing the
technician to visually see that the test strip is contacted with
the discharged wash water) allows the technician to test or measure
pH, bleach concentration or other chemical characteristics of the
discharged wash water (e.g., either leaking wash water or water
that is intentionally being discharged). For example, inserting a
test strip through access port 110 allows the technician to know if
a squeeze tube on a chemical dispenser (e.g., for detergent,
bleach, softener, etc.) has gone bad, which is often the case where
the pH or bleach concentration is either too high or too low.
Photographs in the Appendix of the above referenced provisional
application show a bank of such chemical dispensers configured to
draw chemical from 5 gallon containers of the appropriate chemical
(e.g., detergent, bleach, softener, etc.) for metered delivery to
the washing machine. As described above, in order to preserve the
longest life possible for the linen being laundered, it is
important that the bleach concentration, detergent concentration,
and pH be carefully maintained within a desired narrow range.
Leaking of the wash water through a solenoid valve in need of
repair or replacement makes it very difficult to maintain the
desired levels. Similarly, a squeeze tube or other chemical
dispenser mechanism in need of replacement or repair also makes it
difficult to maintain the desired levels. As described above, where
a system is out of whack due to such issues, within a week or two,
linen being laundered looks awful, and will need to be replaced,
which is an enormous expense.
[0060] The Appendix attached to the provisional application
includes materials relative to cost of linen, rate at which linens
are stained, costs to attempt to reclaim stained linens (e.g.,
about 90% of stained linen can typically be reclaimed in a
subsequent washing--at higher chemical concentrations than a normal
washing). Such reclaim loads more than double the water and labor
consumed as compared to what would be needed if the reclaim load is
made necessary in the first place because of a leak in the drain
pipe system of the commercial washing machine. Of course, for such
reclaim loads, the cost of chemicals is dramatically higher than
for a normal load, because higher chemical concentrations are used,
and additional chemicals not used in a normal washing are also
often added.
[0061] Table 1 below provides an example of chemical costs and
water usage for a normal load of white towels on two (UniMac and
Milnor) exemplary 60 lb capacity commercial washing machines.
TABLE-US-00001 TABLE 1 Breakdown cost on chemicals, water and linen
Chemical cost per load based on a white towel formula on a 60 Lb
industrial washer Laundry Product Size $ per pail $ per gal $ Per
Once Oz per load $ per load Detergent 5 Gallon Pail $124.00 $24.80
$0.19 3.5 $0.68 Bleach 5 Gallon Pail $37.75 $7.55 $0.06 3.5 $0.21
Neutralizer 5 Gallon Pail $101.25 $20.25 $0.16 2 $0.32 Softener 5
Gallon Pail $71.75 $14.35 $0.11 2 $0.22 Total cost per load $1.43
Time Cycle Water level Gallons used Temp Breakdown on water for a
white towels formula on a 60 lb industrial Uni Mac washer Two
minutes Per wash High 24.4 Warm Seven minutes Wash Low 14.4 Hot
Seven minutes Wash Low 14.4 Hot Two minutes Wash High 24.4 Hot Two
minutes Wash High 24.4 Medium Four minutes Wash Low 14.4 Medium
Seven minutes Final Extract Wash Time 27 minutes Total gallon 116.4
Total time with fills 38 minutes Breakdown on water for a white
towels formula on a 60 lb industrial Milnor washer Two minutes Per
wash High 35 Warm Seven minutes Wash Low 11 Hot Seven minutes Wash
Low 11 Hot Intermediate Extract 2 min Two minutes Wash High 28 Hot
Two minutes Wash High 13 Medium Intermediate Extract 2 min Four
minutes Wash Low 26 Medium Seven minutes Finale Extract Wash Time
35 minutes Total gallon 124 Total time with fills 48 minutes On
this Salt Lake City Hilton Property they used 67,800 cubic feet of
water on a 30 day billing cycle that's $746.66 This property has
two 60 Lb washers washing on average 12 loads a day that's 1396.8
gallons a day going down the drain if the drain system is clogged
or the drain solenoid is not working properly. There are 7.480
gallons of water in a cubic foot. Below is a conversion chart How
Many CF Cost per Total on water Enter how many cubic feet used
67,800 0.011012684 $746.66 How many gallons used and cost per
gallon 507,144 0.001472284 $746.66 Cost of the linen being washed
on a 60 Lb industrial washer Linen Cost per How many Total Bath
Mats $2.44 100 $244.00 Bath Towels $4.11 150 $616.50 Hand Towels
$1.04 240 $249.60 Washcloths $0.64 240 $153.60 Pool Towels $4.63
150 $694.50 King Flat $8.42 24 $202.08 King Fitted $8.22 24 $197.28
King Mattress Pad $13.63 24 $327.12 King Bedskirt $30.47 15 $457.05
Queen Flat $7.10 30 $213.00 Queen Fitted $7.27 30 $218.10 Queen
Mattress Pad $10.98 30 $329.40 Queen Bedskirt $27.80 18 $500.40
Full Flat $6.85 30 $205.50 Full Fitted $6.98 30 $209.40 Full
Mattress Pad $9.89 30 $296.70 Pillow Cases $1.52 216 $328.32 Queen
Duvet Covers $24.35 5 $121.75 King Duvet Covers $25.67 5 $128.35
Sage Blanket $32.61 22 $717.42 King Coverlett $117.00 15 $1,755.00
Queen Coverlett $112.00 15 $1,680.00 King Duvet $35.00 22 $770.00
Queen Duvet $33.00 7 $231.00 Pillow Protectors $1.28 216 $276.48
Kitchen Towels $0.00 260 $0.00 Crib Sheets $5.70 45 $256.50
[0062] Table 2 below provides an example of chemical costs and
water usage for a reclaim load of white towels on two (UniMac and
Milnor) exemplary 60 lb capacity commercial washing machines.
TABLE-US-00002 TABLE 2 Breakdown cost on chemicals, water and linen
Chemical cost per load based on a Reclaim formula on a 60 Lb
industrial washer A Reclaim load it is a last ditch effort to save
the linen before being forced to rag it. A reclaim load requires
more chemicals. Before starting the Reclaim load the user pours in
a packet of Power Wash and two cups of S-99. Typically, 90% of
stained linen can be saved. Laundry Product Size $ per pail $ per
gal $ Per Once Oz per load $ per load Power Wash 15 .times. 1 24 oz
$65.50 $4.37 1 packet 1 packet $4.37 S-99 use 2 cups 50 Lb box
$77.04 $1.54 $0.10 2 $0.19 Detergent 5 Gallon Pail $124.00 $24.80
$0.19 5 $0.97 Bleach 5 Gallon Pail $37.75 $7.55 $0.06 5 $0.29
Neutralizer 5 Gallon Pail $101.25 $20.25 $0.16 2.5 $0.40 Softener 5
Gallon Pail $71.75 $14.35 $0.11 2 $0.22 Total cost per load and
customer saves 90% of stained linen $6.44 Time Cycle Water level
Gallons used Temp Breakdown for a Reclaim formula on a 60 lb Uni
Mac industrial washer 30 min Reclaim Wash High 24.4 Hot Two minutes
Per wash High 24.4 Hot Two minutes Per wash High 24.4 Hot Seven
minutes Wash Low 14.4 Hot Seven minutes Wash Low 14.4 Hot Two
minutes Wash High 24.4 Hot Two minutes Wash High 24.4 Medium Four
minutes Wash Low 14.4 Medium Seven minutes Final Extract Total time
72 minutes Total gallon 165.2 Breakdown for a Reclaim formula on a
60 lb Milnor industrial washer 30 min Reclaim Wash Medium 35 Hot
Two minutes Per wash High 13 Hot Two minutes Per wash High 13 Hot
Seven minutes Wash Low 11 Hot Seven minutes Wash Low 11 Hot
Intermediate Extract 2 min Two minutes Wash High 28 Hot Two minutes
Wash High 13 Medium Intermediate Extract 2 min Four minutes Wash
Low 26 Medium Seven minutes Finale Extract Total time 72 minutes
Total gallon 150
[0063] Powerwash and S-99 are simply examples of products from one
manufacturer that can typically be added to a reclaim load, in a
last ditch effort to save the linen. Such products are generally
added to provide increased concentrations of detergents, destaining
agents, and to drastically increase the pH (e.g., sodium hydroxide
or other caustics). For example, the pH in a reclaim load may be as
high as 13 or 14.
[0064] As shown in Tables 1 and 2, for such a 60 lb load of white
towels, the loss in linen cost is over $600 if the stained towels
cannot be reclaimed. Although 90% of the material in the reclaim
load can typically be saved if the system is working properly,
where there are leaks or other problems as described herein, the
percentage saved can be significantly lower. Even if they can be
reclaimed, it costs twice or more the labor costs (to have the
operators run the load through again, as a reclaim load), and there
are chemical costs of over $6 (4 to 5 times that of a normal load)
for the single reclaim load, and the water usage is an additional
150-165 gallons. This does not include the costs associated with
electricity to run the reclaim load, natural gas (or electricity)
to heat the additional 150-165 gallons of water used in the reclaim
load, or the volume of water wasted as a direct result of the
leaking solenoid valve.
[0065] The appendix attached to the provisional application
includes similar data for a larger 80 lb capacity washing machine.
As will be apparent, for such larger washing machines, the losses
are even greater.
[0066] When such wasted resources and costs are multiplied over a
large number of commercial washing machines, over a large number of
installations (e.g., hotels, prisons, universities, assisted living
centers, nursing homes, cruise ships, hospitals, cleaners, etc.)
the waste and cost becomes very large. The savings and conservation
achieved by each installation, and within a metropolitan area as a
whole (particularly a relatively arid region such as areas of the
western United States where water is scarce) becomes significant
and very large.
[0067] Thus, although the systems and methods described herein are
simple and relatively easy to implement, the advantages associated
with their use and implementation would make a significant
difference in those communities where implemented.
[0068] The present invention may be embodied in other specific
forms without departing from its spirit or essential
characteristics. The described embodiments are to be considered in
all respects only as illustrative and not restrictive. The scope of
the invention is, therefore, indicated by the appended claims
rather than by the foregoing description. All changes which come
within the meaning and range of equivalency of the claims are to be
embraced within their scope.
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